My dad was working on a fuel tank filler neck for an old truck. The filler neck was going to connect to a rubber hose so it needed a bead put on it. I built the following tubing beader in about 10 minutes out of a set of crappy chinese locking pliers I had laying around.
I drilled a 5/16" hole in a piece of 1/4" thick plate and cut that in half for the bottom jaw. I welded a piece of a 1/4" bolt to the upper jaw. Make sure that you have the flat area behind the bolt on the upper jaw or it will just curl the edge of the pipe over. I added some weld and filed it down to create that part of the upper jaw.
Here are some pics of the completed tool, and the results on steel tubing, I would think that aluminum would be even easier to work with.
